Polaris General Xl Fender Flare Installation Instructions

Tired of your Polaris General XL kicking up a storm of mud, rocks, and water every time you hit the trail? We’ve all been there. That impressive rooster tail looks cool for a second, but it’s brutal on your machine’s paint, your gear, and anyone brave enough to ride shotgun.

Fender flares are the ultimate solution, but a botched installation can look sloppy, rattle on the trail, or even damage your UTV’s body panels. You need a process you can trust, built on real-world experience.

Imagine a cleaner ride, better protection for your investment, and a more aggressive, finished look for your rig. With the right guidance, you can achieve a professional-quality installation right in your own garage. This guide provides the complete polaris general xl fender flare installation instructions you need to get the job done right the first time, with no guesswork.

Why Bother? The Top Benefits of Adding Fender Flares

Before we grab the tools, let’s talk about why this upgrade is one of the most practical mods you can make. Understanding the benefits of polaris general xl fender flare installation instructions makes the work that much more rewarding.

Unmatched Mud & Debris Protection: This is the number one reason. Wider flares catch the mud, water, and gravel your oversized tires throw, keeping it off your machine and out of the cab. Your passengers will thank you.
Preserve Your Paint & Plastics: Rocks and debris act like a sandblaster against your General’s body panels. Flares act as a shield, preventing chips, scratches, and dings that ruin your rig’s finish and value.
Achieve an Aggressive Stance: Let’s be honest, they look awesome. Fender flares give your General XL a wider, more muscular, and complete look, especially if you’re running a wider offset wheel or larger tires.
Stay Compliant: In many areas, regulations require your tires to be covered by the fender. Adding flares can be the difference between a fun day on the trail and a costly ticket.

Before You Begin: Tools, Parts, and Workspace Prep

A smooth installation starts with great preparation. Rushing this step is how you end up with a lost bolt or a scratched panel. Let’s get organized like the pros do.

Essential Tools & Supplies

Most fender flare kits come with all the necessary hardware, but you’ll need your own tools. Having these ready will make the job a breeze.

Socket Set with Ratchet & Extensions: You’ll likely need 10mm and 13mm sockets.
Torx Bit Set: Polaris loves Torx bolts. A T25, T30, and T40 are common.
Drill with Drill Bits: Some kits require drilling new holes. A sharp set of bits is crucial. Start with a smaller pilot hole.
Plastic Trim Removal Tool Kit: Highly recommended. This prevents you from scratching your plastics when prying off factory push-rivets. A flathead screwdriver is a recipe for damage.
Pop Rivet Gun: Check your kit’s instructions; many use pop rivets for a secure, factory-finish fit.
Rubbing Alcohol & Microfiber Towels: For cleaning mounting surfaces to ensure a tight, clean fit.
Safety Glasses: Non-negotiable. Protect your eyes from dirt and debris.

Workspace and Vehicle Prep

Set yourself up for success. A clean machine in a well-lit area is half the battle.

First, give your General XL a thorough wash, paying special attention to the wheel wells and the underside of the existing fender lips. You can’t get a good fit on a dirty surface. Park it on a level surface with plenty of room to work around all four corners. Engaging the parking brake is a critical safety step.

Your Step-by-Step Polaris General XL Fender Flare Installation Instructions Guide

Alright, let’s get to the main event. Here is how to polaris general xl fender flare installation instructions are broken down, corner by corner. We’ll start with the front. While kits vary slightly, the core process is very similar.

Pro Tip: Lay out all your parts on a clean blanket or piece of cardboard. Identify the front left, front right, rear left, and rear right flares. They are side-specific!

Step 1: Front Fender Flare Installation (Driver’s Side)

Remove Factory Hardware: Using your Torx bits and socket set, remove the factory bolts and plastic push-rivets that hold the stock fender in place. Use your trim removal tool to pop the rivets out cleanly without breaking them.
Clean the Mounting Surface: With the hardware removed, wipe down the entire mounting surface on the vehicle’s body with rubbing alcohol. This removes any wax, grease, or dirt, ensuring the new flare sits flush.
Position the New Flare: Carefully hold the new, larger fender flare in place. It should contour perfectly to the body lines. Loosely start a few of the supplied bolts by hand to hold it in position.
Align and Mark Drill Holes (If Required): If your kit requires new holes, this is the most critical step. With the flare held firmly in place, use a marker or paint pen to mark the drill locations through the holes in the new flare. Double-check the alignment before marking.
Drill Pilot Holes: Remove the flare. Using a small drill bit (e.g., 1/8″), drill a pilot hole at each mark. This prevents the larger bit from “walking.” Then, use the final drill bit size specified in your kit’s instructions.
Secure the Flare: Reposition the flare. Install all supplied bolts, washers, and nuts, or use your pop rivet gun for any rivet locations. Do not overtighten initially. Get everything snug, but not fully torqued.
Final Torque: Once all hardware is in place, go back and tighten everything evenly. The goal is a snug fit that won’t vibrate loose, but over-tightening can crack the plastic flare or strip the hardware.

Repeat this entire process for the front passenger’s side, ensuring a symmetrical installation.

Step 2: Rear Fender Flare Installation (Driver’s Side)

The rear installation is similar to the front but often involves the dump bed area.

Remove Existing Hardware: Just like the front, remove the Torx bolts and push-rivets along the edge of the rear fender and bed.
Clean the Surface: Use your rubbing alcohol and a clean towel to prep the mounting area for a perfect fit.
Test Fit and Align: Position the new rear flare. The rear flares often have more complex shapes to match the body lines around the bed. Take your time to ensure it’s seated correctly.
Mark and Drill (If Necessary): If your kit requires drilling, carefully align the flare and mark your holes. Check for any wiring or components behind where you’re drilling.
Install Hardware: Secure the flare using the provided hardware. Start all bolts and rivets loosely to allow for minor adjustments.
Final Tightening: Work your way around the flare, tightening all hardware to a firm, snug fit. Check the alignment one last time before the final torque.

Finish the job by repeating these steps on the rear passenger’s side. Your installation is now complete!

Pro Tips and Common Problems with Polaris General XL Fender Flare Installation Instructions

Even the best instructions can’t account for everything. Here are some polaris general xl fender flare installation instructions tips and solutions to common issues that we’ve learned in the shop.

Installation Best Practices

Don’t Skip the Test Fit: Before drilling any holes, always do a full test fit. This helps you spot any alignment issues early on.
Warm Up the Plastic: If you’re installing in a cold garage, the plastic flares can be stiff. Let them sit inside your house for a few hours to become more pliable and easier to work with.
A Helping Hand: While you can do this solo, having a friend hold the flare in place while you align and mark holes makes the job significantly easier and more accurate.
Read the Dang Instructions: We know, we know. But seriously, the instructions included with your specific kit will have torque specs and hardware placements unique to that brand. Use our guide as the master process and their sheet for the fine details.

Troubleshooting Common Problems

Problem: A gap exists between the flare and the body.
Solution: This is usually an alignment issue. Loosen all the hardware, push the flare flush against the body, and re-tighten in a different sequence, starting from the center and working your way out.
Problem: A bolt is spinning and won’t tighten.
Solution: You’ve likely stripped the threads. You may need to use a slightly larger bolt and nut (a nutsert is a great pro-level fix) or, in a pinch, a high-quality plastic body rivet.
Problem: The holes don’t seem to line up perfectly.
Solution: Factory tolerances can vary slightly. Use a round file or a drill bit to slightly elongate the hole in the flare (not the vehicle body) to give yourself a little wiggle room.

Post-Installation Care: The Polaris General XL Fender Flare Installation Instructions Care Guide

You’re done! But the job isn’t over. Proper care ensures your new flares last as long as your rig. This is also where we can apply some sustainable polaris general xl fender flare installation instructions by maximizing the product’s lifespan.

After your first real ride, go back and check every single bolt and rivet. Vibrations can sometimes cause new hardware to settle and loosen slightly. Re-torque as needed.

When washing your General, avoid using harsh, abrasive cleaners or stiff brushes on the flares, as this can cause swirl marks. A quality automotive soap and a microfiber mitt are all you need. To restore that deep black look, use a plastic-safe protectant (like 303 Aerospace Protectant), not a greasy, silicone-based tire shine.

Finally, being eco-friendly means minimizing waste. The high-quality TPO plastic used in most aftermarket flares is incredibly durable. By caring for them properly, you avoid the need for replacements, which is the most sustainable practice of all. Recycle the cardboard packaging and dispose of any old, broken factory parts responsibly.

Frequently Asked Questions About Polaris General XL Fender Flare Installation Instructions

How long does this installation take for a DIYer?

For a first-timer with the right tools, plan on about 2-3 hours. An experienced mechanic can likely get it done in 90 minutes. The key is not to rush; take your time with alignment and drilling.

Do I have to drill new holes in my Polaris General?

It depends entirely on the brand of fender flares you purchase. Some are designed to use only factory mounting points for a no-drill installation, while others (often those offering maximum coverage) require drilling a few new holes for added stability.

Can I install these fender flares by myself?

Absolutely. It is a one-person job. However, as mentioned in our pro tips, having a second person to help hold the large flares in place while you get the first few bolts started can make the process faster and less frustrating.

What is the best way to clean my new fender flares?

The best method is simple hand washing with a gentle automotive soap and a soft wash mitt. For stubborn mud, pre-soak it with a hose. Avoid automatic car washes with harsh brushes and aggressive, acidic wheel cleaners that can stain the plastic.

With your new fender flares installed, you’re ready to tackle the trails with less mess and more style. This is a truly satisfying DIY project that enhances both the form and function of your Polaris General XL. Now get out there, stay a little cleaner, and enjoy the ride.

Happy wrenching from the crew at FatBoysOffroad!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.